Download Ambirad VSXUS Troubleshooting guide

ASSEMBLY, INSTALLATION & SERVICING
MANUAL FOR AMBIRAD VSXUS
INFRA-RED HEATERS
INDEX
Section
Introduction and Document Index
Installation Requirements ------------------------------------------------1
Assembly Instructions -----------------------------------------------------2
Start Up Instructions -------------------------------------------------------3
Servicing Instructions ------------------------------------------------------4
Spare Parts ------------------------------------------------------------------5
Troubleshooting Guide ---------------------------------------------------6
Replacing Parts -------------------------------------------------------------7
User and Operating Instructions ---------------------------------------8
WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause property damage,
injury or death. Read the installation,
operating and maintenance instructions
thoroughly before installing or servicing this
equipment.
Introduction.
Welcome to the new range of high efficiency
AmbiRad VSXUS infra-red heaters. Local
regulations may vary and it is the installer’s
responsibility to ensure that such regulations
are satisfied.
and servicing is undertaken on radiant tube
heaters specified in these instructions, due care
and attention is required to ensure that working
at height regulations are adhered to at the
mounting heights specified.
All installation, assembly, commissioning and
service procedures must be carried out by
suitable qualified competent persons and
conform with local building codes, or in the
absence of local codes, with the National Fuel
Gas Code ANSI Z223.1/NFPA 54 or the
National Gas and Propane Installation Code
CSA B149.1
PLEASE READ this document prior to
installation to familiarize yourself with the
components and tools you require at the various
stages of assembly.
All Dimensions shown are in inches unless
otherwise stated.
The manufacturer reserves the right to alter
specifications without prior notice.
When assembling, installing, commissioning
Document Index.
1 Installation Requirements
3 Start Up Instructions
1.1 Health & Safety
1.2 Packing and Shipping Information
1.3 Heater Suspension
1.4 Wall Mounting
1.5 Clearance to Combustibles
1.6 Gas Connection & Supply Details
1.7 Electrical Connections
1.8 Ventilation Requirements
1.8.1 Unflued Units
1.8.2 Vertical Venting
1.8.3 Horizontal Venting
1.8.4 Fresh Air Intake
1.9 Flue & Combustion Air Inlet
1.10 Technical Details
3.1 Tools Required
3.2 Start up procedure
4 Servicing Instructions
4.1 Tools Required
4.2 Burner Description
4.3 Burner Removal
4.4 Burner Gas Injector Servicing
4.5 Burner Head and Electrode Servicing
4.6 Combustion Fan Assembly
4.7 Radiant Tube Servicing
4.8 Heat Exchanger Servicing
4.9 Reflector Servicing
4.10 Sweeping of Flue
4.11 Re-commissioning after Service
2 Assembly Instructions
2.1 Tools Required
2.2 Identification Check List
2.3 Prior to Assembly
2.4 Assembly Instructions
2.4.1 Turbulators
2.4.2 Brackets, U bolts and U bend
2.4.3 Reflectors
2.4.4 End Caps
2.4.5 Canopies
2.4.6 Canopy End Caps
2.4.7 General
2.4.8 Detailed Assembly Drawings
5 Spare Parts
6 Troubleshooting Guide
7 Replacing Parts
7.1 Burner Controller Replacement
7.2 Air Pressure Switch Replacement
7.3 Gas Valve Replacement
8 User and Operating Instructions
8.1 To Start Heater
8.2 To Switch Off Heater
8.3 Servicing
Improper installation, adjustment,
alteration, service or maintenance
can cause property damage, injury or
death. Read the instructions thoroughly
before installing of servicing this
equipment.
2
1. Installation Requirements.
Flex Gas Connector*
Tube Couplings
1.1
Health and Safety
A.
Heater is intended for heating
non-residential indoor spaces and should
only be installed where flammable gases
or vapors are not generally present.
Heaters may be suspended either
horizontal or at an angle, or may be wall
mounted. See section A3 for clearance
dimensions.
The installation must conform with local
building codes or, in the absence of local
codes, with the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 or the Natural
Gas and Propane Installation Code, CSA
B149.1.
The unit shall be electrically grounded
accordance with National Electric Code
ANSJJNFPA 70-1987.
The heater may be installed in aircraft
hangars installed in accordance with the
Standard for Aircraft Hangars, ANSI/
NFPA 409 and in automotive garages
when installed in accordance with the
Standard for Parking Structures, ANSI/
NFPA 88A, or the Standard for Repair
Garages, ANSI/NFPA 88B, or the
Canadian Natural Gas and Propane
Installation Code, CSA B149.1, and are
so marked.
Ensure that minimum clearances will be
maintained to vehicles parked below the
heater.
B.
C.
D.
E.
1.2
(Chain etc)
* Connector must comply with ANSI Z21.24/CSA 6.10.
Shipping packages for individual projects will be
boxed and crated as outlined in the specific bill
of lading.
1.3
Heater Suspension
Attachment to the heater support lugs should be
made by a ‘speed link’, D shackle or in the case
of drop rods, a closed formed hook. The
hanging attachments to overhead steelwork
etc. must be purpose made to good sound
engineering practice or of a proprietary type
fixing. They must be adequately fixed and
designed to carry the whole weight of the
heater. In the event of suitable roof steelwork
being unavailable, additional steelwork should
be fitted to enable vertical hangers to be used
for suspending the heaters.
These methods are illustrated in Figure 1. If
there are any doubts as to the strength or
suitability of roof steelwork to which heaters are
to be suspended, please refer to a Consultant,
Architect or owner of the building.
It is recommended that the heater is raised to its
final position once the assembly of the tube/
bracket/reflector has been completed. Longer
tube assemblies may be raised in more than
one sub-assembly with final tube connection
made in the air.
Packing and Shipping Information
See section 2 for assembly drawings. Material
list with part numbers and descriptions for each
part will accompany each shipment.
The suggested mounting heights for AmbiRad
heaters are given in table 1 below.
Heaters include:
Burner/Control
Heat Exchanger
Radiant Tubes
Reflectors/Canopies
Brackets
Fan
U-Bend
1.4
Options:
Wall Mounting
These radiant tube heaters can be wall mounted
using the appropriate bracket.
Ball Valve
Vent Hoods
Hanging Assembly
When using the wall mounting brackets the
heater must be inclined at an angle between 35°
and 55°.
Table 1. Recommended Mounting Heights
Model
Mounting Height (ft)
Standard
Inclined
min
recommended
min
recommended
90
14
16
12
13
140
16
18
14
15
3
*
*
*
VSX models
Vertical orinclined
suspension on this
plane is acceptable.
*
*
4
Vertical suspension chain ideal.
Where supports are inclined
max. recommended angle of
inclination 15°
15° max
Shackle method of attachment. Pin must
be tightened by pliers
Drop rod with formed hook.
n.b. hook or eyebolt must be
closed tight after installation.
Alternative method of suspending
‘U’ tube and linier type heaters.
IMPORTANT: THE HEATER SHOULD SLOPE DOWNWARDS TOWARDS THE RETURN BEND
BY APPROX. 10mm FOR BOTH HORIZONTAL AND WALL MOUNTED INSTALLATIONS.
Ensure that there is adequate provision
in the building for combustion and
ventilation air supply. Installation must
meet minimum requirements and
applicable codes.
Were chain supports have an
angle of inclination greater than
15° an equal and opposite
support is recommended.
Figure 1. Recommended Methods of Heater Suspension.
1.5
Clearance to Combustibles.
The minimum clearances to combustible materials are given in the tables below. These
minimum distances MUST be adhered to at all times.
Figure 2 Diagram illustrating the clearance to combustibles
C2 or C3
C1
E
A
B
D1
or
D2
B
VSX models
B
A
Table 2. Clearances to combustibles VSXUS
VSXUS90 (ins)
VSXUS140 (ins)
Below Tubes
A
82
90
To the Sides
B
35
35
Above Reflector
C1
4
4
Above Burner / Heater Outlet Vented
C2
20
20
Above Burner / Heater Outlet Unvented
C3
24
24
Behind Burner
D1
32
42
Behind Burner with Vent connected
D2
24
24
F
21
21
End Wall
WARNING:
Minimum clearance from the heater must be maintained from vehicles parked below heater.
In all situations, clearances to combustibles must be maintained. Signs should be posted in
storage areas to specify maximum stacking height to maintain required clearance to
combustibles. Refer to mounting clearance tables.
5
1.6
Figure 3. Correct orientation of Ball Valve
Gas Connection and Supply
WARNING: Before installation, check
that the local distribution conditions,
nature of gas and pressure, and adjustment
of the appliance are compatible.
Gas Flow
The gas connection on the heater is ½”N.P.T
external thread.
Gas Flow
Injector sizes and manifold pressure for the
burners are shown in the table 3. The gas
supply piping and connections must be installed
so that the minimum pressure stated is
achieved.
Figure 4. Correct Installation of Flexible
Gas Connection
A gas shut off valve and union should be fitted
in the gas supply line close to the heater and a
⅛” N.P.T plugged tapping, accessible for test
gauge connection, provided immediately
upstream of the appliance gas inlet.
It is essential to provide some flexibility in the
final gas connection preferably by use of an
approved flexible gas connector or stainless
steel expansion loop.
Take care when making a gas connection
to the heater not to apply excessive turning
force to the internal controls.
Depending on the specific installation, the
flexible gas hose may be routed to the gas cock
at any of the following angles in relation to the
burner:
Care must be taken to observe the minimum
pipe bend diameter (minimum 10”, maximum
14”) & pipe expansion distance (minimum 1⅛”,
maximum 3¾”).
The correct installation as shown will allow
for approx 4” of movement due to expansion.
WARNING:
CONNECTOR MUST BE INSTALLED IN A “U” CONFIGURATION. USE
ONLY THE 36” LONG CONNECTOR OF ½” NOMINAL ID THAT WAS
FURNISHED WITH THIS HEATER.
6
WARNING: FIRE OR EXPLOSION HAZARD - Expansion of the radiant pipe occurs with
each firing cycle causing the burner to move with respect to the gas line. This can
result in a gas leak producing an unsafe condition. It is therefore essential to provide some
flexibility in the final gas line connection - preferably by use of an approved armoured
flexible connector or stainless steel expansion loop as shown in the drawings.
Table 3 Gas Supply Pressures
Natural Gas
Gas Type
Max Supply Pressure (in W.C)
10.0
Min inlet gas supply (in W.C)
7.0
Connection ½” N.P.T internal thread
Gas Supply
1.7
It is recommended that the electrical circuit
controlling the heater or group of heaters
include thermostats and if required manual
control switches. All such controls and switch
gear must be rated to handle the total inductive
load of the circuit they control. For large
installations the use of relays or contactors
should be considered.
Electrical Connections
WARNING: Before making electrical
connections, switch OFF the main
electrical disconnect. There may be more
than one disconnect switch. Lock out
and tag switch with a suitable warning
label. Electrical shock can cause
personal injury or death.
Control panels are available from the
manufacturer incorporating multiple Black Bulb
Thermostats controlling up to 10 heaters per
thermostat for zone control of the heated area.
This appliance must be electrically grounded
Supply 120V 60Hz single phase.
Standard heater 0.16HP.
Current rating 1.2 amp max (inductive).
Fuse: external 3 amp.
(Control
Panels
are not A.G.A/CSA
design
certified)
Important: All electrical work should be done by
a qualified electrician in strict accordance with
the National Electrical Code ANSI/NFPA 70. or
Canadian codes CSA C22.1
Where alternative
manufactures’
controls are used,
please refer to
their
instructions
for their siting and
installation details.
The electrical supply to the heater is by three
wires: live, neutral and ground connections.
Install in accordance with all state & local
codes.
Figure 5. Typical VSXUS Wiring Connections
Switch with
Fuse
Fan plugs into burner
7
Figure 6. Internal Burner Wiring Diagram.
FAN
L
BROWN
VACUUM
SWITCH
N
SOLENOID VALVE
N.C.
C.
N.O.
GREEN
2
1
3
BURNER
POWER INPUT
WHITE
VALVE
J.S.T.
GREEN
N
L
WHITE
WHITE
WHITE
BURNER
ON
POWER
ON
GREEN
WHITE
BROWN
BROWN
1
2
BLACK
MAIN J.S.T.
9
10
3
4
7
8
PURPLE
11 12
YELLOW
GREY
BROWN
IGNITOR
LAMPS
FLAME SENSOR
BLACK
YELLOW
GREY
BROWN
WHITE
If any of the original wire as supplied with the appliance must be replaced, it must be replaced
with wiring material having a temperature rating of at least 220°F/105°C
Figure 7. External Wiring Schematic.
(Two Zones)
Zone 1
Heater 1
Heater 2
Heater 4
Heater 3
Double pole insulator
adjacent to each
heater
Thermostats
Zone 1
Zone 2
* Frost Thermostat
Double pole
fuse isolator
120v
1ph 60Hz
{
* Time
switch
Zone 2
* Manual
switch
L
N
G
8
Heater 5
Heater 6
1.8 Vent Requirements and Details
1.8.1 Unvented units
The terminal should be at least 3ft away from
any air intake to the building
Heaters maybe installed without a vent
providing the governing building codes are met
and consideration is properly given to
possibilities of condensation on cold surfaces.
If the heater is equipped with ducted combustion
air, the vent terminal must be at least 3ft away
from the air inlet and located higher than the
inlet.
Installation shall meet the
requirements when unvented:
The vent terminal must be protected from
blockage by snow. Refer fig 7a & b
•
•
•
following
Internal volume of the heated room must
be greater than 214cu.ft. per 100 BTU/
HR of heaters installed.
OR
Natural or mechanical means shall be
provided to supply and exhaust at least 4
CFM per 1000 BTU per hour input of installed heaters.
Combustion gasses shall not impinge on
combustible materials with a temperature
in excess of 150°F.
1.8.4 Fresh Air Intake
Whenever the heater is installed in locations
where airbourne dust or other pollutants are
present, a fresh air supply should be ducted to
the burner.
A fresh air duct of 4” dia. Should be installed
from the fresh air to the air intake connection on
the fan housing. A flexible jointing piece should
be installed at the fan connection with hose
clamps to facilitate expansion and contraction.
1.8.2 Vertical venting
The maximum recommended length air duct is
25ft and the maximum number of bends is 2.
The minimum length is 18”. The location of the
fresh air duct inlet must be where it will receive
dust free clean air. An inlet cap with bird screen
must be fitted at the inlet of the duct. If the duct
inlet is located above the roof the underside of
the inlet terminal must be at least 2ft above roof
level and at least 10” above any projection on
the roof within 7ft of the inlet. Intake pipe, fittings
and sealant are not furnished by the
manufacturer. Refer fig 8c
The heater can be installed with a vertical vent.
All vent piping should be adequately supported
from the building structure and terminated with
an approved terminal. All connections should
be properly sealed. refer fig 7a
1.8.3 Horizontal venting
Individual units can be vented horizontally
through side walls. Venting must be installed in
accordance with ANSI Z223.1 (NFPA-54) and
local codes. Recommended terminals are
AmbiRad V0700 for 4” and V0800 for 6” vent.
1.9 Flue and Combustion Air Inlet Options
Maximum length of vent is 25ft with 2 - 90° long
radius elbows.
Dependent on the type of burner fitted to your
heater it is possible to have configurations of
flue and combustion air inlet options to those
shown overleaf:
Runs of 12ft or shorter can use 4” dia vent.
Runs over 12ft should use 6” flue pipe.
Any portion of vent that passes through a
combustible wall must be insulated, or use an
approved insulating thimble.
• Option 1
For flued products of combustion and no
ducted air please refer to Figure 8.a.
Standard vent terminals must extend at least 6”
from the wall and at least 24” from any
combustible overhang. Protect the building
material from degradation by the vent gasses.
• Option 2
For ducted air and products of combustion to
ventilated area please refer to Figure 8.b.
Vent joints should be sealed and secured using
at least 3 sheet metal screws. Should
condensation occur the vent should be
shortened or insulated.
• Option 3
For flued products of combustion and ducted
air via concentric pipe please refer to Figure
8.c.
9
Option 1 - Figure 8.a. Forced Burner with Heat Exchanger (Standard Flue)
For flued products of combustion and no ducted air
Products of combustion
Air
Inlet
Firing tube
Products of combustion
If heaters are installed with no flue the
ventilation instructions detailed in section
1.8 must be applied.
Ducted air must be used in locations
where there is airborne dust or where
there is a polluted atmosphere e.g. Chlorinated
Vapours.
Maximum length = 30ft
Minimum diameter = 4in
Maximum no of bends = 2
A
5ins Twin Wall Flue Pipe
B
5ins to 4ins Reducer
C
4ins Clip
D
4ins Flexible Flue
E
4ins Flexible Flue to Fan
F
Heat Exchanger
G Forced Burner
Refer to section 1.8.3 for Maximum
length of vent.
10
Option 2 - Figure 8.b. Forced Burner with Heat Exchanger (No External Flue)
For ducted air and products of combustion to ventilated area
Fresh
Air
Products of
combustion to
ventilated area
Firing
tube
Products of
combustion
if heaters are installed with no flue the
ventilation instructions detailed in section
1.8 must be applied.
Ducted air must be used in locations
where there is airborne dust or where
there is a polluted atmosphere e.g. Chlorinated
Vapours.
Maximum length = 30ft
Minimum diameter = 4ins
Maximum no of bends = 2
11
A
Forced Burner
B
Heat Exchanger
C
4ins Clips
D
4ins Flexible Flue
E
4ins Flexible Flue to Fan
F
Shroud for unflued heater installation
Option 3 - Figure 8.c. Forced Burner with Heat Exchanger (with Concentric Flue)
For flued products of combustion and
ducted air via concentric pipe
10ins
Products of
combustion
9ins
23ins
54ins
Fresh Air
Inlet
Fresh
Air
Products of
combustion
Firing
Tube
Products of
combustion
if heaters are installed with no flue the
ventilation instructions detailed in section
1.8 must be applied.
Ducted air must be used in locations
where there is airborne dust or where
there is a polluted atmosphere e.g. Chlorinated
Vapours.
Maximum length = 30ft
Minimum diameter = 4ins
Maximum no of bends = 2
Refer to section 1.8.3 for Maximum 12
length of vent.
A
Concentric Flue Terminal
B
4ins Flexible to concentric flue
C
4ins Flexible to Fan
D
Heat Exchanger
E
4ins Clips
F
Forced Burner
G
Flue Extension optional
(10ins/20ins/40ins)
1.10 Technical Details
Table 4 - Technical Details. All heaters to run on Natural Gas (G20)
1
No of Injectors
Gas Connection
½” N.P.T nipple.
Electrical Supply
120 volt 1 phase 60Hz
4” or 6”
Vent size (in)
120 volt 1 phase 60Hz
Unitary Fan Motor Details
1.2A MAX
Current Rating
Electronic Program Start up with Spark Ignition
Ignition
Burner
Size
Nominal
Gross Heat
Input
Burner
Head
Burner Orifice
Plate
Injector
Injector
Pressure
BTU/Hr
Part No.
Part No.
Part No.
Inches WG.
201063-30
201007-30
4.5
201063-26
201007-22
3.4
Pressure
Switch
Min. Heater
Length
VSXUS140
140,000
VSXUS90
90,000
200988
Combustion Fan
Details
Burner
Size
Fan Type
Orifice Part No.
Part No.
U (ft)
VSXUS140
2560-1
M101624-52
201676
17
VSXUS90
201687
3133
201676
12
2. Assembly Instructions.
PLEASE READ this section prior
assembly to familiarise yourself with
components and tools you require at
various stages of assembly. Carefully open
packaging and check the contents against
parts and check list.
to
the
the
the
the
Please ensure that all packaging is
disposed of in a safe environmentally
friendly way.
For your own safety we recommend the
use of safety boots and leather faced
gloves when handling sharp or heavy items. The
use of protective eye wear is also
recommended.
The manufacturer reserves the right to alter
specifications without prior notice.
2.1
Tools Required.
Suitable alternative tools may be used.
The following tools and equipment are advisable
to complete the tasks laid out in this manual.
Saw
Horses
Cordless
Drill
Leather
Faced
Gloves
Phillips
Screwdriver
Wrench
Set
5/16”
Drive
3/16” (5mm)
5/32” (4mm)
Allen
wrenchs
Tape
Measure
13
2.2
Identification check list
COLOUR CODE
VSX90
VSX140
1x
1x
1x
1x
1x
1x
COLOUR CODE
Inner
End Caps
Burner
Outer
Canopy
End Caps
Heat
Exchanger
2x
2x
2x
2x
2x
2x
2x
3x
2x
3x
2x
2x
1x
2x
7
8
13
14
2
4
16
22
6
8
Turbulators
2x
3x
Outer
Canopy
Couplers
3x
4x
12
16
M4
Full Nut
Brackets
M4
Washer
M6
Mudwasher
4
6
6
10
No.5
Torque
Screw
M6
Washer
M6
Full Nut
M6 x 35
Setpin
VSX140
Tubes
U Bend
Inner
Reflectors
VSX90
M6 x 15
Setpin
4
6
M8
Full Nut
7
8
M4 x 10
Pozi Setpin
M8 U Bolt
14
2.3
Prior to assembly
•
Ensure the area in which you are working is safe and clear of obstructions.
•
Identify with the components in the check list and in which order they will be assembled.
•
Arrange the trestles* in a straight line to allow for length of tubes.
•
Remove all protective plastic from underside of Stainless Steel Reflectors / inside of End Caps.
* if saw horses cannot be located, ensure any alternative is sound and can carry the heater weight.
2.4
Step by step installation.
2.4.1 TUBES & TURBULATORS.
1 Locate and position tubes on trestles with the
welded seams of the tubes facing each other.
After deciding which end will have the burner, mark
out the position of the first bracket as shown in the
assembly drawings section. Slide brackets over tubes
as shown.
2x
2x
2 Locate and insert turbulator(s) into tube(s)
ensuring the correct length and quantity are inserted
into the correct tube. See assembly drawings section
for location & length.
2x
3x
CAUTION — SHARP EDGES!
2.4.2 BRACKETS, U BOLTS & U BEND.
3 Fit the M8 U bolts over the tubes into the holes
in the bracket & loosely secure with M8 nuts &
washers, noting that all the brackets on the firing
tube (right hand) except the bracket adjacent to the
U bend should have nuts & washers on both sides
of the bracket to allow bracket to be tightened whilst
still allowing a 3mm gap for expansion between the
tube & U bolt. See assembly drawings section Fig.A.
3x
4x
L/H tube
D0 NOT tighten any of the nuts at this stage.
15
R/H tube
4 Working at the opposite ends of the tubes to
the burner, locate & position two couplers so that
the socket heads are facing outwards & the
pre-fitted bolts in the couplers line up with the
locating holes in the tubes. Do not fully tighten at
this stage.
2x
2x
5 Slide U bend into the open end of the couplers
ensuring the pre-fitted bolts engage in the pre-cut
holes in the U tube section. Tighten all four
clamping bolts to provide a tight grip between
tubes & U tube section.
1x
1x
2.4.3 REFLECTORS
6
Remove protective film before starting.
The reflectors supplied all have the same hole
positions, however, each end reflector should
be positioned with the holes for the end caps
(position arrowed) outermost.
Starting at the burner end, slide the reflectors
through the brackets until they are all roughly in
position along the heater, referring to the assembly
diagram showing overlaps. Measure the distance
between the end of the burner end tubes & the
centre of the end bracket, This should be
150mm, slide bracket along tubes to adjust, then
tighten U bolts on the end bracket.
2x
3x
CAUTION — SHARP EDGES!
7 Slide end reflector so that the innermost
slotted holes line up with 1st bracket fixing holes,
then fix in place using M6 x 35mm pins, washers
& nuts.
2x
2x
16
8 Slide 2nd bracket to line up with innermost
slotted hole in 1st reflector, & bolt together as in
step 9. Bolt 1st & 2nd reflectors together using end
elongated holes in each.
4x
4x
11 Repeat this procedure referring to the assembly diagram for quantities used on specific models, but noting that the final bracket is not bolted
to the reflector. (See photo)
At this stage all the U bolts should be
fully tightened.
10 Locate M4 pins, washers & nuts into holes in
overlapping reflectors as shown.
1x
2x
1x
2x
1x
2x
2.4.4 END CAPS
11 Using M4 setpins & washers fix the blank end
cap beneath the the reflector profile at the U bend
end with the flanges facing outwards.
3x
3x
3x
3x
2x
2x
12 Using M4 setpins & washers fix the 'cut out'
end cap beneath the reflector profile at the
burner end with the flanges facing outwards.
3x
3x
3x
3x
17
2.4.5 CANOPIES
13 Remove protective film before starting.
Slide the outer canopies over the reflectors from
the U bend end ensuring correct location in reflector profile. Line up burner end canopy flush
with burner end reflector. Overlap canopies as
shown in the assembly diagram.
2x
3x
CAUTION — SHARP EDGES!
14 Adjust canopies so that the holes on top align
with each other as detailed in the assembly
instructions. Locate and fix one No.5 torque screw
on every canopy overlap.
1x
2x
2.4.6 CANOPY END CAPS
15 Locate 6 off No.5 torque screws. Position the
blank canopy end cap with the end cap flanges
facing inwards, beneath the canopy profile at the
U bend end & fix with screws. Repeat procedure
for 'cut-out' canopy end cap, again ensuring the
flange faces inwards.
2x
2x
12x 12x
CAUTION — SHARP EDGES!
2.4.7 GENERAL
16 The heater assembly is now complete and can now be installed. We would recommend that the
burner and heat exchanger be assembled once the heater has been installed in the roof space.
1x
1x
1x
1x
18
Figure 9. VSXUS Heater Assembly
2.4.8 Detailed Assembly Drawings
6”
The following pages show the technical
dimensional details of the VSXUS range of
heaters.
5’ - 5”
6’ - 2”
5”
4’ - 6”
2” O/LAP
2” O/LAP
2”
19
VSXUS140
2” O/LAP
19’ 5” REFERENCE
4’ - 6”
2” O/LAP
VSXUS90
2” O/LAP
6’ - 5”
11’ - 2” TUBE
6”
2” O/LAP
17’ - 1” TUBE
Please note the heater type, length and
reference number from the delivery/advice note
before identifying the correct model drawing.
Figure 10. VSXUS Heater Breakdown (3 module VSXUS140 shown)
20
3. Start Up Instructions.
These appliances should be commissioned by a qualified mechanical contractor.
3.1
Tools Required.
The following tools and equipment are advisable
to complete the tasks laid out in this manual.
Leather
Faced
Gloves
Small Flat
Head
Screwdriver
Phillips
Screwdriver
½”
Spanner
3.2
Suitable alternative tools may be used.
5/32” (4mm)
Allen
Wrench
Manometer
Large Adjustable
Wrenches for fitting
Of Gas Flex.
Multimeter
producing a spark at the ignition electrode. The
gas solenoid valve will at the same time be
energised and the ‘burner on’ lamp will
illuminate. If the ignition is successful the flame
is detected by the flame sensing probe and the
‘burner on’ lamp will remain on.
Start Up procedure
Inspect installation and ensure that it has been
carried out in accordance with these
instructions. Remove burner and inspect the
electrode assemblies ensuring these are
securely fixed and all electrical connections
securely made.
If ignition is unsuccessful the gas valve will close
and the spark ignition de-energized after
approximately 10 seconds. For approximately
10 to 20 seconds the fan will purge the system
then re-ignition will be attempted. After 2 further
attempts at ignition the control unit will ‘lock-out’,
the ‘power on’ lamp will remain illuminated and
the fan will continue to run. To reset after
‘lockout’ switch off the power supply to the
system and wait 2 minutes. Then turn the power
on. If repeated ‘lockout’ occurs investigate the
cause.
Re-fit the burner ensuring that it is correctly
positioned and the screws are fully tightened.
Ensure that electrical and gas supplies are
isolated.
The gas supply should be purged and tested for
soundness in accordance with local and
National Safety codes.
Open isolating gas valve and test gas
connections for soundness using soap solution.
Set burner gas pressure as follows:
Switch off the power supply to the heating
system. Connect a ‘U’ tube manometer to the
pressure test point provided on the combination
gas control valve. Remove the cover from the
pressure regulator revealing the adjustable
screw. Start the heater and using a suitable
screwdriver adjust the pressure regulator,
turning the screw clockwise to increase the
pressure or counter-clockwise to decrease the
pressure. Set the pressure to appropriate inches
w.c. from the table of gas pressures and orifice
plate dimensions for correct heater description.
Switch off the power supply to the heating
system. Disconnect ‘U’ tube manometer, then
securely replace screw in pressure test nipple.
Open the control housing door by unscrewing
the securing screw. Ensure all internal
components are securely fixed and all
connections securely made.
Open the manual gas valve outside the control
housing
Switch on the electrical supply to start the
heater and observe the correct start up
sequence. Ensure that the setting of any time
switch and thermostat are such that the heating
system will be required to operate.
The fan will start to run and the ‘power on’ lamp
will illuminate. Safe-start checks are carried out
automatically. After the fan has run up to full
speed and a satisfactory pressure condition has
been established, the ignition sequence will
commence. The spark ignition will be energized
Check the operation of the flame safeguard
equipment as follows:
With the heater running normally, switch off the
gas supply at the shut off valve. The heater
21
should attempt to relight and if the gas valve
has been left off ‘lock-out’ should occur
indicated by the ‘power on’ lamp being
illuminated and fan running, but the ‘burner on’
lamp being off.
With the heater running normally, pull off the
silicone rubber tube connecting the vacuum
switch to the combustion chamber. Within 4
seconds the burner should shut off. Then
replace the tube securely and observe that the
heater proceeds to ignite in the normal way.
Check the operation of the pressure proving
switch as follows:
Close the controls door securing it with the
screw.
Commissioning chart
Check installation has
been carried out to these
instructions.
Ensure gas and electricity
supplies are isolated.
Disconnect gas hose from
burner
Remove burner from tube and inspect burner head.
(See servicing instructions)
Replace burner on tube
and secure.
Reconnect gas hose.
Open isolating valve.
Check soundness.
Check thermostat is set to
maximum and is calling
for heat.
Open control housing and
check that all components
are securely fastened.
Switch on electrical supply.
The red neon should now
be illuminated. If restarting
heater a delay of 15s
should be allowed.
Turn off power and check
that all components are
securely fastened.
The heater should now
run through its start up
sequence and ignite.
NO
A successful ignition is indicated
by the amber light illuminating
and remaining illuminated.
Has the
burner lit?
YES
Check operation on flame failure.
Check gas pressure.
Check gas pressure.
Leave the instructions
with a responsible person.
Close control housing
22
Check operation of
air pressure switch.
4. Servicing Instructions.
These appliances should be serviced annually by a competent person to ensure safe
and efficient operation. In exceptional dusty or polluted conditions more frequent
servicing may be required. Servicing work should be carried out by a qualified mechanical contractor.
4.1
Tools Required.
Suitable alternative tools may be used.
The following tools and equipment are advisable
to complete the tasks laid out in this manual.
4.2
Leather
Faced
Gloves
Phillips
Screwdriver
½”
Spanner
4mm
Allen
Wrench
Large Adjustable
wrenches for fitting
of Gas Flex.
Small Flat
Head
Screwdriver
Multimeter
Manometer
Burner Description.
Figure 11. Burner breakdown
A
Ignition Controller
B
Gas Valve
H
Ignitor Assembly
C
Burner On Amber Neon
I
Jet Carrier
D
Power On Red Neon
J
Combustion Fan
E
Injector
K
Pressure Switch
F
Burner Tube
L
Gaskets
G
Pepperpot Head
M
Burner Head Wiring Harness
23
Soft
Brush
4.3 Burner Removal
Step 1 Isolate power and gas supplies.
Step 2 Unplug the power connectors.
Step 5 Slacken the set screw on the burner
support casting to enable the burner to be
removed from the radiant tube.
Step 6 Remove the burner and position
the burner in a safe area to prevent the
burner or components attached to the burner
from falling to the ground.
Step 3 Detach the gas supply as shown below,
taking care to support the burner connection.
Step 4 If ducted air is connected, slacken
hose clip and remove the flexible hose from the
burner.
4.4 Burner Gas Injector Servicing
Step 1.a Remove the burner support casting
and gasket.
Step 5 slacken the jubilee clip attaching the
pre-heated air hose to the heat exchanger and
remove the flexible hose from the burner.
Step 1.b The burner head assembly can be
disconnected by separating the connectors of
the ignition lead assembly and removing the
pressure switch silicon tube.
24
replaced ensuring the 5 holes on the outer ring
are aligned alongside the probes.
Step 2 The gas injector can be inspected and
replaced if contaminated or blocked.
Step 3 The condition of the igniter assembly can
be checked for deterioration. However, we
advise replacement at each service to ensure
continued reliability. Detach the electrode
assembly from the burner head by removing the
two screws and separating the igniter lead
connectors.
When replacing the gas injector ensure
approved thread sealant is used.
Step 3 Reconnect ignition leads and silicone
tube to test nipple. Refit gasket and support
casting.
Step 4 Refit the electrode assembly and ensure
the connections are secure to prevent arcing of
the spark electrode.
4.5 Burner Head and Electrode Servicing
Step 1 Check the pepper pot burner head for
contamination. If necessary this can be
removed. See below. This can be cleaned
together with the Inside of the burner head.
Step 5 Check the positions and spark gap as
shown below.
Step 6 The burner assembly is ready to refit
after servicing the combustion fan and the
radiant tube assembly.
Step 2 The pepper pot burner head can be
25/64”
10.0°
1 7/64”
±5/64”
3/8”
2 13/64” ±13/64”
Ø3”
7/64”
±1/64”
25/64”
25
4.6 Combustion Fan Assembly
Step 1 If ducted air is fitted, slacken hose
clamp and remove the flexible hose from the
fan.
Step 7 Ensure the impeller rotates freely.
Step 8 Refit components.
Step 2 Remove fan screws and unplug from
burner box.
4.7 Radiant Tube Servicing
Step 1 Brush any dust from the exterior of the
tubes.
Step 2 Inspect the fan and burner tubes visually.
If the tubes appear clean, skip to servicing the
reflector.
Step 3 Remove the U bend.
Step 3 The combustion fan can now be
detached.
Step 4 Withdraw the turbulators from the
appliance. Carefully noting their condition and
position. Replace turbulators if necessary.
Step 4 Remove the fan orifice plate spigot and
spinning.
Step 5 Inspect the impeller and remove any
dust with a soft brush.
Step 6 Remove any dust from fan scroll and
from around the motor.
Step 5 The turbulators should be cleaned with a
soft brush.
26
If necessary the reflectors can be cleaned with a
mild detergent. This can significantly improve
the efficiency of the appliance.
4.10 Sweeping of Flue
Inspect the fresh air inlet duct and vent to
ensure they are free from any blockage or
obstruction. The air inlet terminal and vent
terminal should be inspected to ensure they are
not liable to obstruction.
Step 3 If required the interior of the tubes can
then be cleaned using an industrial vacuum
cleaner or by using long poles and a scraper.
4.11 Recommissioning After Service
After servicing of the heater has been
undertaken, it will be necessary to
re-commission the heater as detailed in Section
11 of these instructions.
Step 4 Refit components.
4.8 Heat exchanger Servicing
Step 1 Remove the flue connections
Step 2 Slacken casing support screws and
remove heat exchanger from the radiant tube.
Step 3 Remove any dust and dirt from the
heat exchanger & refit.
4.9 Reflector Servicing
The condition of the reflectors should be noted.
27
5. Spare Parts.
Required Spares
Note Any spare part components that are
not approved by AmbiRad could invalidate
the approval of the appliance and validity of the
warranty.
In order to aid troubleshooting and servicing we
recommend that the components shown in this
section should be stocked.
Item
Description
Part No.
Item
Description
Part No.
201508
201697
201676
Ignition
Controller
3256-11
Pressure Switch
VPLUS40
VPLUS200
Others
Valve
Twin sol reg
201706
Amber Neon
(Burner On)
2181
Pepperpot Head
200988
Red Neon
(Mains On)
2176
Ignitor Assembly
201284
Combustion Fan
VPLUS200
Others
2560-1
201687
Burner Tube
200358
Gasket Set
201488
Injector
See
section 1.11
Ducted Air Hose
201321
Jet Carrier
(40 - 150)
200420
Hose Clamp
7541
900225-2
Tube Insert
201705
VSXUS 90 ONLY
Cables:
Spark Electrode
(black)
Rectification lead
(purple)
Earth lead
(green/yellow)
900225-3
Turbulator
200015T
VSXUS 90 ONLY
900225-1
28
6. Troubleshooting Guide.
Ensure gas & electricity
supplies are enabled.
YES
YES
Does the RED
neon
illuminate?
NO
Is there power
on the burner?
NO
YES
Does the
Fan run?
NO
Check:
1. Wiring harness & plugs
2. Vacuum switch operation
3. Replace fan
NO
NO
If the heater still fails to
operate normally,
please contact
your local
representative.
Check:
1. Vacuum switch tubes
2. Emitter tubes, air inlet & flue
for obstructions
3. Operation of vacuum switch
4. Replace fan
Check:
1. Ignition controller
2. Wiring harness
3. Amber neon faulty
Does the
vacuum switch
`pull in`?
YES
YES
Does the
amber light
illuminate for 10s
then go out?
Check:
1. Operation of any thermostat
2. Any external fuses
3. Correct voltage is selected
NO
YES
Does the
amber light
illuminate after
10s purge?
Check:
1. Ignition controller
2. Red neon faulty
YES
Is the burner
sparking?
NO
Check:
1. Integrity of spark leads
2. Integrity of electrode
assembly & spark gap
3. Ignition controller
YES
Does the gas
valve open?
NO
Check:
1. Ignition controller
2. Replace gas valve
Check:
1. Burner inlet pressure
2. Burner nozzle pressure
3. Check live & neutral polarity
4. Check presence of good ground
YES
29
7. Replacing Parts.
7.2 Air Pressure Switch Replacement
Turn of gas any electrical supplies to
the heater before starting repair work..
Step 1 Open left hand door. Disconnect the two
silicone impulse tubes.
7.1 Burner Controller Replacement
Step 1 Slacken screw in burner lid and open the
right hand burner access door.
Step 2 Disconnect burner controller from the
wiring harness.
Step 2 Remove the two screws as shown below.
Step 3 Disconnect the HT Lead from burner
controller
Step 3 Remove electrical connections. The air
pressure switch can now be removed.
Step 4 Fit the new air pressure switch ensuring
the impulse tubes are connected as shown
below.
Step 4 Remove the two screws attaching the
controller to the burner and remove.
Step 5 Fit new burner controller
Step 6 Refit leads
Step 5 Test product and close access doors.
Step 7 Test product and close access door.
30
7.3 Gas Valve Replacement
Step 1 Remove the burner assembly as
described in the Servicing Sections.
Step 6 Detach the two screws holding the front
of the gas valve.
Step 2 Open the right hand access door and
detach the burner controller from the wiring
harness.
Step 7 Remove the four screws holding the rear
burner plate in position.
Step 3 Open the left hand access door and
detach the impulse hoses from the air pressure
switch.
Step 8 Remove the rear plate.
Step 4 Remove the 4 screws holding the burner
head onto the burner assembly.
Step 5 The burner head can now be detached
by disconnecting the impulse tube and the
burner head wiring.
Step 9 The jet carrier, gas inlet, and wiring
harness can now be detached from the gas
valve.
Step 10 The two screws retaining the gas valve
can then be removed.
Step 11 The gas valve can now be replaced.
Step 12 Refit all components.
Step 13 Set pressures and ensure reliable
burner performance.
31 Step 14 Test product and close access door.
8. User & Operating Instructions.
AmbiRad is the manufacturer of a series of tubular infra-red heaters designed for overhead heating
of industrial and commercial buildings. Individual heating units are suspended from the roof or
mounted at an angle on the wall
8.1
1.
This appliance must only be installed by qualified craftsmen in accordance with
the requirements of local and National Codes.
2.
This appliance must be grounded in accordance with the National Electrical
Code ANSI/NFPA No.70 or Canadian Codes.
3.
Never rest anything, especially ladders against the heaters.
lamp will remain illuminated and the fan will
continue to run. To reset after ‘lockout’,
switch off the power supply to the heater
and wait 5 minutes. Then turn the power on.
If repeated ‘lockout’ occurs investigate the
cause.
To Start the Heater
1. First ensure that the gas supply to each
heater is turned on by opening the main
gas shut off valve.
2. Ensure that the setting of any time switch
and thermostat are such that the heating
system will be required to operate.
8.2.
3. Switch o the electricity supply to the
heater. The fan will start, the ‘power on’
light on the burner will illuminate and
ignition commence.
To Switch Off Heater
1. Switch off electrical supply to the heater.
The burner will stop and the fan will shut off.
4. Ignition will occur.
8.3.
Servicing
1. To ensure continued efficient and safe
operation it is recommended that the heater
be serviced regularly by a qualified person
every year in normal working conditions but
in exceptionally dusty or polluted conditions
more frequent servicing may be needed.
Document reference number US/VS/19/0708
5. If ignition is successful the gas valve will
close and the spark ignition de-energize
after approximately 10 seconds. For
approximately 10 - 20 seconds the fan will
purge the system then re-ignition will be
attempted. After 3 attempts at ignition the
control unit will ‘lock-out’, the ‘power on’
Your Local Representative
Ambi-Rad Limited P.O. Box 617
Fishers, Indiana 46038
Telephone 317-577-0337
Facsimile 317-842-3989
Website www.ambirad.com/us
For the Distributor Nearest please call
1-888-330-4878
32
AmbiRad is a registered trademark of AmbiRad Limited. Because of continuous product
innovation, AmbiRad reserves the right to change product specification without due notice.